CN102350421B - Force position servo control system for automatically cleaning carbon bowl of anode carbon block for aluminum electrolysis - Google Patents
Force position servo control system for automatically cleaning carbon bowl of anode carbon block for aluminum electrolysis Download PDFInfo
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- CN102350421B CN102350421B CN2011101992744A CN201110199274A CN102350421B CN 102350421 B CN102350421 B CN 102350421B CN 2011101992744 A CN2011101992744 A CN 2011101992744A CN 201110199274 A CN201110199274 A CN 201110199274A CN 102350421 B CN102350421 B CN 102350421B
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Abstract
The invention discloses a force position servo control system for automatically cleaning a carbon bowl of an anode carbon block for aluminum electrolysis, comprising five servo driving motors with absolute encoders, two pressure sensors, a torque sensor, a programmable logic controller, a photoelectric switch and a vision system, wherein the programmable logic controller is communicated with the five servo driving motors through a field bus and connected with the pressure sensors and the torque sensor through an I/O (Input/Output) port; the photoelectric switch is installed at an initial position and a final position of the carbon block and used for locating the carbon block; the vision system is used for locating a carbon bowl center and a chute angle; and the programmable logic controller is used for locating a cleaning tool to the carbon bowl of the carbon block and a chute according to position information obtained by the vision system and controlling the tool to simultaneously clean the carbon bowl and the chute. By using the force position servo control system, full-automatic force position serve control for locating the anode carbon block, measuring the height of the anode carbon block, locating the carbon bowl and the chute and cleaning the carbon bowl and the chute can be realized.
Description
Technical field
The present invention relates to a kind of industrial servo-control system, relate in particular to a kind of power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning.
Background technology
Domestic electrolytic aluminium factory aluminum electrolysis anode carbon block is take petroleum coke as raw material, through operations such as high-temperature calcination, kneading, moulding, roastings, obtain the baked anode piece, the charcoal piece is switched on being articulated in electrolytic cell after the conductive steel pawl is connected, the charcoal piece goes out aluminum metal as anode by electrolysis is replaceable.As shown in Figure 4, charcoal piece upper surface has four blind holes to anode carbon block, about diameter 170mm, and it is the helicla flute of 75 ° that the hole inwall has lift angle, these blind holes are commonly called as the charcoal bowl.The conductive steel pawl is inserted the charcoal bowl and casts firmly, can be sent to electrolytic cell and use.The effect of charcoal bowl spiral inner wall skewed slot is loosening for preventing that the charcoal piece is connected with the conductive steel pawl.
Anode carbon block in roasting process,, for fear of oxidation, is laid a large amount of carbon granules and is protected around anode carbon block.After roasting is completed, understand a large amount of carbon granule of bonding and certain adhesive strength is arranged in anode carbon block surface and charcoal bowl, these carbon granules need to clear up before use.The method for cleaning of the charcoal piece that adopts at present is, with special spades, the carbon granule in charcoal piece surface and charcoal bowl is shoveled, blow away with compressed air again, labor cleaning's charcoal piece generally will be cleared up 2-3 time just can reach qualified requirement, and compressed air can make powdered carbon spread in air, make that charcoal piece cleaning work environment is abominable, workload is large, mobility of people is larger, has potential safety hazard.
Summary of the invention
The purpose of this invention is to provide a kind of power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning.
The objective of the invention is to be achieved through the following technical solutions:
The power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning of the present invention, comprise five servo drive motors that carry absolute encoder, two pressure sensors, torque sensor and visual identity software and hardware system, described five servo drive motors that carry absolute encoder are respectively spindle servo electric machine, skewed slot servomotor, X-axis servomotor, Y-axis servomotor, Z axis servomotor;
Also comprise Programmable Logic Controller, described Programmable Logic Controller is communicated by letter with five servo drive motors, also by the I/O port, with described pressure sensor, with torque sensor, is connected by fieldbus; Three in five servomotors form the three degrees of freedom right angle coordinate robot systems, are used for carrying the cleaning cutter and realize location, all the other two two kinds of tool motions on the cleaning cutter are controlled respectively;
Also comprise that the original position and the final position that are arranged on the charcoal piece are used for the optoelectronic switch that the charcoal piece is positioned;
Also comprise the vision system to charcoal piece De Tanwan center and angle of bevel location;
Can control cutter by power Position Hybrid Control method clears up simultaneously to charcoal bowl and skewed slot.
The optoelectronic switch that is arranged on charcoal piece final position has two, for detection of the charcoal piece, puts in place and leaves with the charcoal piece, realizes doing coordinating of mode with the original production lineman.
Determine employing vision system and the image recognition software of Tan Wan center and angle of bevel position obtain coordinate, then with the motor of the described three degrees of freedom right angle coordinate of PLC control robot, carry out tool setting search realization.
Vision system obtains charcoal bowl coordinate time single charcoal bowl is taken pictures respectively, obtains the relative coordinate of charcoal bowl, then take encoder for servo motor numerical value as reference, calculates absolute coordinate.
Control system adopts the test method under the power restrictive condition to search for the position of charcoal bowl, be that cutter often moves and moves a step in search procedure, cutter test contact charcoal piece, and stop after reaching certain contact force, judge highly by pressing down whether cutter aims at Tan Wan center and skewed slot position.
When PLC controls the physical location at three degrees of freedom right angle coordinate robot searches Tan Wan center, adopted a kind of grid type traversal search mode, namely grid division centered by coordinates computed, carry out the tool setting exploration with fixed step size at X and Y-direction.
The measurement of charcoal tile height is to utilize the method for cutter contact charcoal piece to realize, namely cutter presses down and read force sensor data, and when cutter contacted with charcoal piece upper surface, the encoder numerical value by the Z axis servomotor can access the charcoal tile height.
Working angles limits the pressure of vertical direction and the torsion of skewed slot cutter, closed loop PID control by torsion and the motion of skewed slot cutter has been realized the power Position Hybrid Control, make the skewed slot cutter can be in cutting decline process, automatically rotate cleaning when realizing charcoal bowl and skewed slot along the hand of spiral of skewed slot.
Have the dual touch screen operation interface, wherein touch industrial computer display screen is used for take pictures identification software and monitor charcoal bowl situation of operation charcoal bowl, and graphic control panel is used for operation, control and the process monitoring of whole system.
As seen from the above technical solution provided by the invention, the power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning provided by the invention, owing to comprising Programmable Logic Controller, described Programmable Logic Controller is communicated by letter with five servo drive motors, also by the I/O port, with described pressure sensor, with torque sensor, is connected by fieldbus; Also comprise that the original position and the final position that are arranged on the charcoal piece are used for the optoelectronic switch that the charcoal piece is positioned; Also comprise the vision system to charcoal piece De Tanwan center and angle of bevel location; Described Programmable Logic Controller is according to the charcoal bowl of charcoal piece and the positioning control cutter of skewed slot are cleared up simultaneously to charcoal bowl and skewed slot.After complete the anode carbon block location, automatically complete the survey of charcoal piece high, the tasks such as charcoal bowl and skewed slot location, charcoal bowl and skewed slot cleaning, assurance does not simultaneously damage skewed slot, the inner carbon granule of charcoal bowl is cleaned out and met industrial requirements, the cleaning efficiency of charcoal piece guarantees at 300 pieces/day, reaches the daily output requirement of workshop fully.
Description of drawings
The principle schematic that realizes the power Positioning Servo System that the automation of anode carbon block for aluminium electrolysis charcoal bowl is cleared up that Fig. 1 provides for the embodiment of the present invention;
Fig. 2 is charcoal bowl cleaning system architecture schematic overview in the present invention;
Fig. 3 is cutter structure schematic diagram in the present invention;
Fig. 4 a is Anodic charcoal piece schematic diagram of the present invention;
Fig. 4 b is charcoal bowl schematic diagram in the present invention;
Fig. 5 is power Positioning Servo System flow chart in the present invention;
Fig. 6 is charcoal tile height measuring-signal flow chart in the present invention;
Fig. 7 is charcoal bowl centralized positioning signal flow graph in the present invention;
Fig. 8 is charcoal bowl cleaning signal flow graph in the present invention.
in figure: 1, the raceway installation site, 2, charcoal piece clear position, 3, the 3rd optoelectronic switch emission receives installation site with the second optoelectronic switch, 4., cutter, 5, the X-axis guide rail, 6, the Z axis guide rail, 7, the Z axis servomotor, 8, the Y-axis guide rail, 9, the Y-axis servomotor, 10, the signal lamp installation site, 11, the X-axis servomotor, 12, clamping motor, 13, the 3rd optoelectronic switch receives and the second optoelectronic switch transmitting site, 14, main shaft (M axle) servomotor, 15, the skewed slot motor, 16, pressure sensor, 17, torque sensor, 18, the second cutter head, 19, the first cutter head, 20, the first charcoal bowl, 21, the second charcoal bowl, 22, the 3rd charcoal bowl, 23, the 4th charcoal bowl, 24, skewed slot, 25, charcoal bowl step surface, 26, anode carbon block charcoal bowl, 27, anode carbon block.
The specific embodiment
The power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning of the present invention, realized that the Full-automatic circulation of charcoal bowl cleaning system moves, the Fault diagnosing and protecting function, adopts special-purpose control system and control method to realize its function.This control system combining image recognition technology and field bus technique have solved charcoal bowl coordinate identification orientation problem; utilize simultaneously the cutting force measurement parts to realize the power Position Hybrid Control of charcoal bowl cleaning cutter; high efficiency complete charcoal bowl inner surface and skewed slot by cutting at one time time cleaning, the power measurement component also provides monitor data for fault diagnosis and the self-shield of scale removal process simultaneously.This system has realized whole process control, motion control and force feedback control algolithm by the PLC control module, the method of the cutter milling of first passage main shaft and skewed slot cutter servo-actuated cutting has simultaneously realized the Automatic clearance of electrolytic anode charcoal bowl, and this system also can be cleared up fully for the situation that in the charcoal bowl, the bonding hardness of carbon granule is higher.
Below in conjunction with accompanying drawing, the embodiment of the present invention is described in further detail.
The power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning of the present invention, its better specific embodiment be as shown in Figure 1:
Comprise five servo drive motors that carry absolute encoder, two pressure sensors, torque sensor and a Programmable Logic Controller PLC who communicates by letter with five servo drive motors, is connected with torque sensor by I/O port and pressure sensor by fieldbus.It is characterized in that: anode carbon block installs optoelectronic switch by first device and the second device and positions in the original position at workpiece and final position → by the actual height of vision system antianode charcoal piece De Tanwan center and angle of bevel location → antianode charcoal piece measure → the accurate location → cutter of PLC searching algorithm antianode charcoal piece charcoal bowl and skewed slot clears up simultaneously to charcoal bowl and skewed slot.
First device is arranged on the original position of charcoal piece, and charcoal piece preparation is sent signal to control system; The second device is arranged on the final position of charcoal piece, and the situation that puts in place of charcoal piece is sent signal to control system.
Optoelectronic switch with a plurality of second device places.
Do not arrive at the charcoal piece, during initial or final position, in the situation of the optoelectronic switch false triggering that badly causes due to site environment, can not cause the misoperation of mechanical system.
Robotic vision system and PLC searching algorithm Dual positioning are adopted in location to charcoal bowl and skewed slot.
The communication modes of robotic vision system and PLC adopts RS232.
To the location finding of charcoal bowl, it is the complement mark signal that the second cutter head enters the charcoal bowl, and when namely current Z axis encoder numerical value and the first cutter head arrive charcoal piece upper surface, whether the difference of Z axis encoder for servo motor numerical value is greater than certain numerical value.
Control system adopts the some striking to search for the position of charcoal bowl, i.e. the certain distance of the every movement of cutter, click once downwards, determines whether to arrive the center of charcoal bowl.
The warning judgement that control system is searched for the charcoal bowl is that the force feedback of pressure sensor exceeds restriction.
The judgement of concrete hunting zone is the X-direction of system permission and the worst error of Y direction.
Control system to the Y direction judgement of charcoal bowl search be by pressure sensor the first cutter head and charcoal piece Surface Contact the time, the force feedback of two pressure sensors is different to be judged.
The measurement of charcoal tile height is that the Z axis encoder numerical value during by the contacting of cutter and charcoal piece upper surface is determined.
The charcoal tile height measurement judgement that puts in place is force feedback numerical value by two pressure sensors limits value while surpassing the cleaning of charcoal bowl.
During surveying height, spindle servo electric machine drives the first cutter head with torque mode and rotates, and walks clearly the lip-deep carbon granule of charcoal piece.
During the search skewed slot, the second cutter head keeps the certain contact force with charcoal bowl step surface.
The realization that maintains contact force is the input take the force feedback of pressure sensor as PID, and PID is output as the position of the second cutter head in the vertical direction.
The recurrent pulse mode of PID triggers, the relative displacement of output the second cutter head in the vertical direction.
During the search skewed slot, A axle servomotor drives the second cutter head with torque mode and rotates, and the position of controlling the second cutter head in the vertical direction by the force feedback of torque sensor simultaneously is the position of cutter on Z-direction.
During the search skewed slot, the force feedback by pressure sensor judge the second cutter head whether arrive skewed slot directly over.
During the search skewed slot, the force feedback of pressure sensor surpasses in the situation of restriction, and control system PLC can give a warning.
The warning that control system is sent can show alarm lamp, touch-screen and the alarm buzzer on the switch board panel.
The carbon granule that cleaning charcoal bowl is inner and charcoal bowl skewed slot is interior is cleared up simultaneously.
The Position Control mode of charcoal bowl skewed slot is the PID SERVO CONTROL.
The servo-controlled force feedback that is input as torque sensor of PID, be output as the relative displacement of the second cutter head in the movement of skewed slot inside.
The power of torque sensor feedback is the suffered horizontal tangential power of six blades of the second cutter head.
Between charcoal bowl clear-up period, the cephalomotor spatially spiral line that conforms to the skewed slot shape of the second cutter is that the angle that PID by control system regulates the second cutter head realizes.
Behind the position of finding charcoal bowl and skewed slot, control system can be drafted desirable planning curve to position and the shape of charcoal bowl and skewed slot.
Control system is carried out match to the level of the second cutter head and the motion of vertical direction and desirable planning curve, allows certain error.
Specifically the force feedback during with normal cleaning comprehensively relatively judges according to the force feedback of pressure sensor and torque sensor for the damage situation control system of charcoal bowl.
The judgement whether the first cutter head arrives the bottom of charcoal bowl is that the difference of the Z axis encoder for servo motor numerical value when surpassing default value and current Z axis encoder numerical value and arriving charcoal piece upper surface with the first cutter head of the force feedback numerical value by pressure sensor is greater than the numerical value of presetting.
Control object of the present invention is mainly the tooling system of charcoal bowl cleaning system.Control system when realizing charcoal piece clearing function, has also given charcoal bowl cleaning system comprehensive automatic operating ability.Can overcome that anode carbon block surface temperature in anode carbon block production is high, the charcoal bowl shape is irregular, carbon granule sticks to charcoal piece surface and the randomness of charcoal bowl inside is large, electromagnetic interference is strong, the undesirable elements such as the high pollution of carbon dust and electric conductivity are on the impact of control system.Overcome that the input manpower that exists in prior art is many, large on human health damage, production efficiency is low, cost is high, be subjected to the deficiencies such as subjective factor affects greatly, contaminated environment; The invention provides a kind of strict efficient, low input, high production, non-environmental-pollution, easy to operate, automaticity is high, need not the professional, can reach the control system of complete monitor anode charcoal piece charcoal bowl cleaning by man-machine interface.
In the present invention, the PLC system is written into the control algolithm program,, by set flow process,, according to the information of sensor feedback, to servomotor, sends instruction, controls servomotor work and stops;
Human-computer interface system and PLC system produce interactive information, complete the operations such as condition monitoring, default value modification, manual operation, troubleshooting of control system.
Wherein the communication modes of PLC and five servo drive motors is the Canopen bus;
The data of described torque sensor and pressure sensor collection are transferred to PLC by the I/O data acquisition module of PLC;
The cleaning control program that in system, the main technology that adopts has servomotor control technology, pressure measurement technology, torque measurement technology, I/O data acquisition technology, I/O data filtering technology, data time-domain analysis technology and PID control technology etc. to combine with anode carbon block explained hereafter streamline; The hunting zone of PLC automatic search program scheme is the error worst error of vision system feedback anode carbon bowl centre coordinate and angle of bevel coordinate.
Below the cleaning of location, charcoal bowl and skewed slot how to realize the measurement of charcoal tile height, the centralized positioning of charcoal bowl, skewed slot illustrated respectively:
The charcoal tile height is measured: the anode carbon block upper surface has the part carbon granule, has certain hardness and adhesion.Before the charcoal bowl cleaning of carrying out anode carbon block, at first cutter is moved to the top of anode carbon block, the absolute encoder that utilizes the Z axis servomotor to carry, can record the position that Z axis is fixed a cutting tool at any time.Z axis descends, start simultaneously the torque mode of spindle servo electric machine, the first cutter head is rotated with certain moment of torsion, when cutter contacts with the anode carbon block surface, the first cutter head can be removed the adhesion carbon granule on anode carbon block surface, and the numerical value that records of two pressure sensors by cutter top determines whether cutter arrives actual charcoal piece surface.Adopting this scheme is to consider that tooling system itself has certain flexibility, and the flexibility of cutter can protect the cutter head of cutter and pressure sensor to be without prejudice in the ordinary course of things; If adopting routine techniques measures, even ignore cost and technical problem, record the very high data of precision, in the situation that cutter itself has flexibility, the theoretic charcoal bowl degree of depth even Z axis has descended, but the cutter head of cutter still can not arrive the charcoal bowl bottom, the carbon granule of charcoal bowl inside can not be cleaned out fully.
The centralized positioning of charcoal bowl: the initial position of cutter is given coordinate position by vision system; The search of antianode charcoal piece charcoal bowl, the currency crest of the pressure at both sides sensor by cutter changes, judge that the second cutter head enters the situation of charcoal bowl: (the first cutter head has certain surplus than the charcoal bowl, even the charcoal piece is positioned with certain error, also can enter the charcoal bowl,) the second cutter head will enter the charcoal bowl, its positioning precision need to reach 2mm; Position error (be generally the 6mm left and right on X-direction, be generally the 4mm left and right on Y direction) according to the charcoal piece; Cutter descends according to predetermined anode carbon block charcoal bowl position, and have two algorithms this moment: one is more than the second cutter head enters charcoal bowl 8mm, thinks that the second cutter head enters the charcoal bowl, starts to search for skewed slot; Two is that the second cutter head probes into the degree of depth of charcoal bowl less than 8mm; Trigger search utility, on X-direction, the charcoal bowl is searched for, with a striking search Tan Wande center, namely with certain step-length, substep carries out, when not arriving the position at X-direction Tan Wan center, two of tops of the cutter pressure sensor numerical value change amounts that cause due to click charcoal piece differ not too large or keep fixing difference, by the time domain curve of cyclical fluctuations that forms after the output data filtering of observing two pressure sensors, can be judged accurately; When arriving X-direction position, Tan Wan center, the time domain curve of cyclical fluctuations that forms after output data filtering according to two pressure sensors, the variable quantity of two pressure sensors has obvious difference, and the site error that can infer thus the second cutter head is in the positive direction of Y-axis or negative direction; Y direction is being searched for,, with less step-length, clicking search, finding charcoal bowl center;
The search of antianode charcoal piece skewed slot: the second cutter head enters 8mm left and right in the charcoal bowl, need to find the position of skewed slot on the step surface of charcoal bowl inside, the second cutter head is pressed in (size of pressure guarantees in certain scope) on step surface, this process is with the output of two pressure sensors, input as pid control algorithm, then the displacement that the output of pid algorithm of using is regulated as Z axis position trace, thus reach the purpose that the second cutter head and charcoal bowl step surface are maintained contact force; Simultaneously, with certain moment of torsion, rotate the second cutter head, when running into larger adhesion carbon granule, the second cutter head Speed Reduction, Z axis rises cutter, keeps simultaneously the second cutter head to be pressed on step surface with certain pressure, until six blades of the second cutter head enter skewed slot.
the cleaning of antianode charcoal piece charcoal bowl: after determining the angle of the center of charcoal bowl and skewed slot, cutter rises, and withdraws from the charcoal bowl, holding position is constant, starts spindle servo electric machine, and the first cutter head starts with constant revolution, starts cutter fast-descending pattern, near the charcoal piece, apart from charcoal piece 5mm place, the Z axis servomotor is switched to torque mode to start to descend, and start simultaneously the power Positioning Servo System of skewed slot servomotor this moment, enters skewed slot, in skewed slot, six blades of the second cutter head will be subject to the power effect of both direction, be respectively: the power on vertical direction and the side force on blade, the vertical direction power that blade is subject to produces while being the cleaning carbon granule, do not do independent measurement and monitoring, the power sum that it and the first cutter head are subject to while clearing up the inner carbon granule of charcoal bowl is reflected on the numerical value change of two pressure sensors simultaneously, when the output numerical value change of two pressure sensors is excessive, cutter stops descending, and certain height that rises, protection cutter head and pressure sensor, side force on blade is to need the strict power of controlling, consider the width large 4mm of the width of charcoal bowl skewed slot than blade, the target of power position servo control is that blade only is subject to the power on vertical direction, and side force is zero, but six skewed slot techniques of charcoal bowl are for being distributed in the inner surface of charcoal bowl with spatially spiral shape, six blades of the second cutter head want to arrive the bottom of charcoal bowl, unavoidably to contact with the inwall of skewed slot, produce the tangential force that forms circumference with six blades, the second suffered tangential force of cutter head can directly record by torque sensor, in case surpass the moment of torsion that normal rotation needs, to trigger the skewed slot servomotor the second cutter head will be carried out position adjustments, the direction of position adjustments is identical with the direction of tangential force, this adjusting is to use torque sensor to record tangential force and change input as pid control algorithm, pid control algorithm is output as the angle that the second cutter head rotates, the accumulative total maximum of this angle can not surpass the difference of oblique cutter groove and blade, this adjusting is carried out in real time, can say that the second cutter head is under this pattern, be to be in a kind of dynamic equilibrium state, this dynamic equilibrium state makes the spatially spiral curve of the movement locus of blade when clearing up the charcoal bowl with skewed slot for skewed slot technique, conforming to of the second cutter head just.Thereby the cleaning effect that has guaranteed charcoal bowl and skewed slot meets the requirements.
The effect that the present invention can reach is: after complete the anode carbon block location, automatically complete the survey of charcoal piece high, the tasks such as charcoal bowl and skewed slot location, charcoal bowl and skewed slot cleaning, assurance does not simultaneously damage skewed slot, the inner carbon granule of charcoal bowl is cleaned out and met industrial requirements, and the cleaning efficiency of charcoal piece guarantees the daily output requirement that reaches workshop fully at 300 pieces/day.
, below in conjunction with accompanying drawing, to case study on implementation of the present invention, be further described in detail as follows:
As shown in Fig. 2, Fig. 3, Fig. 4 a, Fig. 4 b, charcoal bowl cleaning system is mounted on anode carbon block 27 production lines, the charcoal piece 27 of producing is directly processed, at first, system pushes charcoal piece 27 by signal lamp 10 notices, and signal lamp 10 has two lamps: green for pushing the charcoal block signal, red light is for starting to clear up the anode carbon block signal, signal lamp 10 carries buzzer, sends waiting signal.Production line pushes anode carbon block 27 and enters charcoal bowl cleaning system control conveying device, and the first optoelectronic switch is checked through charcoal piece 27, starts the raceway motor, and charcoal piece 27 is sent into clear position 2.In order to guarantee the accurate positioning of charcoal piece, for the conveying device motor, band-type brake is installed, use two pairs of optoelectronic switches---the second optoelectronic switch and the 3rd optoelectronic switch; At first charcoal piece 27 arrives the second optoelectronic switch position, PLC detects the second optoelectronic switch and starts, send halt instruction to the raceway motor, detect simultaneously the state of the 3rd optoelectronic switch, the state of the 3rd optoelectronic switch can be directly relevant to the initial position of anode carbon block charcoal bowl 26.The position of two optoelectronic switches differs certain distance, and their state can guarantee the site error of charcoal piece 27 in allowed limits; PLC controls clamping motor 12 and clamps charcoal pieces 27, and X-axis servomotor 11 drives cutters 4 and moves along the X-axis positive direction, and minute three steps are four charcoal bowls 26 take pictures (initial position can be taken pictures for the first charcoal bowl 20); PLC is by serial ports and vision system communication, and vision system is responsible for taking pictures and is calculated the coordinate of each charcoal bowl, and sends to PLC, and PLC determines the precalculated position of each charcoal bowl according to the coordinate of receiving, the error of coordinate that vision system sends is generally at ± 3mm.
As accompanying drawing 5, flow chart shown in Figure 6, at first cutter 4 is moved to the center of two charcoal bowls 26, starting pressure sensor 16 defence programs, this program is divided two kinds: one, algorithm for correct measurement charcoal piece 27 height, when pressure sensor 16 outputs reached in this pattern setup pressure value scope, the first cutter head 19, cutter 4, pressure sensor 16, guide rail can work, and can correctly record the charcoal tile height; Its two, be the algorithm of protection cutter sensor 16 and guide rail, when pressure sensor 16 outputs reached in this pattern setup pressure value scope, the first cutter head 19, cutter 4, pressure sensor 16, guide rail may break down, and it is highly on the low side to record charcoal piece 27; The range of pressure values of these two kinds of patterns is to determine according to the excursion of pressure sensor 16 in the range of pressure sensor 16 and scale removal process, here said pressure sensor 16 output numerical value refer to that two pressure sensors 16 of cutter 4 tops are single and overall, be that pressure sensor 16 output does not exceed prescribed limit and refers to that not only the output of single pressure sensor 16 surpasses prescribed limit, and require the output sum of pressure sensor 16 also to surpass prescribed limit; Consider that cutter 4 is rigid element, the first cutter head 19 is taked fast approaching with contacting of charcoal piece, and contact, start spindle servo electric machine 14 torque mode simultaneously at a slow speed, and the first cutter head 19 starts to rotate, and can remove anode carbon block 27 upper surface overwhelming majority carbon granules.After the first cutter head 19 compressed the charcoal piece, saltus step appearred in the output of pressure sensor 19, and PLC records current Z axis servomotor 7 encoder numerical value, and as the height of charcoal piece 27, Z axis guide rail 6 rises simultaneously, and the first cutter head 19 and charcoal piece 27 are separated.Charcoal piece 27 height of measuring by this method need to be corrected when charcoal bowl location determination, because PLC is the situation of charcoal bowl that enters as the judgement cutter head according to displacement that Z axis descends, rectification is the plastic deformation that will remove due to cutter 4 itself, the error that cutter head decline displacement is caused.
Flow chart as shown in Figure 7, after determining the height of anode carbon block 27, according to the coordinate position that vision system provides, PLC controls servomotor moving cutting tool 4 and arrives the centre coordinate position of the 4th charcoal bowl 23, and the direction of adjusting 19 two blades of the first cutter head is X-axis guide rail 5 directions; Starting pressure sensor 16 pattern of protecting of trying hard to keep, while Z axis fast-descending, near anode carbon block 27, in the certain distance in distance anode carbon block surface 1, Z axis switches to slow speed mode, prepares to enter anode carbon block charcoal bowl 26, in Z axis decline process, PLC can judge whether the first cutter head 19 and the second cutter head 18 enter charcoal bowl 26 and skewed slot 24, whether meets the condition of normal cleaning charcoal bowl 26; Have three main criterions in charcoal bowl 26 search main programs: 1, whether the first cutter head 19 enters charcoal bowl 26; 2, whether the second cutter head 18 enters charcoal bowl 26; 3, whether six of the second cutter head 18 blades enter skewed slot 24.How many PLC is to the displacement that these three judgements show as Z axis and descend with respect to the charcoal tile height position after correcting, as when Z axis 6 current locations with respect to the charcoal tile height position after correcting less than 30mm, think that six blades of the second cutter head 18 have entered skewed slot 24, complete the location of charcoal bowl 26.
for the judgement 1 in charcoal bowl 26 location main programs, the first 19 two of cutter heads blade is in X-axis 5 directions, so can not consider the error of Y-direction cutter 4, as long as the position of cutter 4 in the error of X-axis 5 directions in error range, the first cutter head 19 just can enter charcoal bowl 26, simultaneously in order to ensure charcoal bowl 26 can the cleaning rate, be also the first cutter head 19 design one cover search utilities, at first cutter 4 is moved to charcoal bowl error of coordinate extreme position along X-axis 5 negative directions, start search take this position as starting point, step-length of every movement, the first cutter head (19) is clicked once downwards, after each click is completed, Z axis 6 rises rapidly, prevent that pressure sensor 16 from transfiniting, if Z axis 6 down positions, lower than the certain distance in charcoal tile height position, think that the first cutter head 18 enters the charcoal bowl.Between the both positive and negative polarity extreme position, total step number is determined, the search step number surpasses total step number to be thought, the charcoal bowl damages, and can not search the charcoal bowl.
Judgement 2 in charcoal bowl 26 location main programs, surpass 25mm if the first cutter head 18 enters the displacement of charcoal bowl 26, and (the vertical direction distance of the first cutter head 19 and the second cutter head 18 is 15mm) thinks that the second cutter head 19 also enters charcoal bowl 26; If can not enter charcoal bowl 26, start the second cutter head 18 search utilities, at first Z axis 6 rises, and the initial position that the limit of error position of moving cutting tool 4 to second cutter heads 18 or the first cutter head enter the charcoal bowl rotates simultaneously the second cutter head 18 and makes that wherein a pair of blade is parallel with Y-axis 8 directions, start to search for charcoal bowl 26, step-length of every movement, the second cutter head (19) is clicked once downwards, after each click is completed, Z axis 6 rises rapidly, prevents that pressure sensor 16 from transfiniting; After each click is completed, analyze the change curve of two pressure sensors 16 and the degree of depth that the second cutter head 19 probes into the charcoal bowl by PLC, if meet the feature of specific change curve, and probeing into the degree of depth does not meet the demands, think that the second cutter head arrives charcoal bowl X-axis 5 direction centers, but also there is position error in Y-axis 8 directions.Analyze by the change curve to two pressure sensors 16, can draw the direction of error of the second cutter head 18, withdraw from simultaneously charcoal bowl 26, Y-axis 8 directions move a step-length; Again click charcoal piece 27; Until probeing into the degree of depth of charcoal bowl 27, the second cutter head 19 satisfies condition; X-axis 5 with Y-axis 8 because its error range is determined, so their total search step numbers separately determine, reach total search step number and still do not meet the condition that enters charcoal bowl 26, think, this charcoal bowl 26 damages, and can not search charcoal bowl 26.
For the judgement 3 in charcoal bowl 26 location main programs, if Z axis 6 down positions think that lower than charcoal piece 27 height 35mm six blades of the second cutter head 18 enter skewed slot 24; Otherwise start skewed slot 24 search utilities; Start PID first and regulate, it is to be output as input with pressure sensor 16 that this PID regulates, and Z axis 6 needs mobile relative displacement to be output, and the Real Time Monitoring that carries out is regulated; These six blades that are adjusted in the second cutter head 18 for the first time are triggered while compressing the step surface 25 of charcoal bowls 26; Skewed slot motor 15 torque mode start, and drive the second cutter head 18 and rotate in the counterclockwise direction; At this moment, if the second cutter head 18 stops operating, expression runs into larger carbon granule, Z axis 6 rises at this moment, and the second cutter head 18 restarts rotation, and PID first regulates the force value of impelling again Z axis 6 decline maintenances and step surface 25 simultaneously; Until find six blades of the second cutter head 18 to enter skewed slot; The hunting zone of the second cutter head 18 is 70 degree, still fails to enter skewed slot 24 after the second cutter head 18 rotates 70 degree, thinks that charcoal bowl 26 damages, and can not enter skewed slot 24; Enter skewed slot 24 when blade is determined, PID first regulates and is closed, and records simultaneously current X-axis 5, Y-axis 8 positions, the encoder position of skewed slot motor 15 (position of skewed slot 24), and then Z axis 6 rises, and the second cutter head 18 withdraws from charcoal bowl 26.
Flow chart as shown in Figure 8, determine charcoal bowl and the dovetail trench postpone of anode carbon block, also need to correct for recording X-axis 5Y axle 8 coordinates, consider that charcoal bowl 26 diameters are larger than the second tool bit diameter, the one direction search enters charcoal bowl 26 and can not reach the center of charcoal bowl 26, so to recording center position coordinates, need to correct; Correction value is that the step-length that moves according to Y-axis and X-axis and the empirical value of experiment draw.Start PID second and regulate, this PID regulate be output valve variable quantity take torque sensor 17 as input, the displacement regulated quantity of the second cutter head 18 is output.The side force that this adjusting can be subject to six blades of the second cutter head 18 in real time is reflected on the position adjustments of the second cutter head 18; The collection that the output data of torque sensor 17 are carried out not is to carry out always, but every 20ms collection once, if the output of torque sensor 17 meets, regulates requirement, drive the second cutter head 18 and move corresponding displacement, otherwise PID is in the monitoring state; Spindle servo electric machine 14 drives the first cutter head 19 to start to rotate, and is responsible for the carbon granule of cleaning charcoal bowl 26 inside; Z axis 6 descends, and six blades of the second cutter head 18 start to enter skewed slot 24, has two kinds of adjustings this moment: the first adjusting is that PID second regulates; The second adjusting is that the output of pressure sensor 16 is regulated; , for the first adjusting,, if torque sensor 17 numerical value increase (reducing), exceed the dead zone range that PID regulates, the certain angle of blade of counterclockwise (clockwise) adjusting the second cutter head 18; , for the second adjusting,, if the single or overall numerical value of pressure sensor 16 surpasses limits value, will trigger Z axis 6 rewind downs actions, with the sensor on protection cutter head and cutter; Under the first adjusting, the second adjusting and Z axis, the effective condition of degradation action is the bottom that cutter head does not arrive charcoal bowl 26; In case arrive the bottom of charcoal bowl 26, will trigger the charcoal bowl program that withdraws from fast of cutter 4; While withdrawing from charcoal bowl 26, PID second regulates and can not be closed, and, until the second cutter head 18 leaves charcoal bowl 26, then, starts the cleaning of lower the 3rd charcoal bowl 22.
Before the 3rd charcoal bowl 22 is positioned, PLC can be to the actual clear position of the 4th charcoal bowl 23, the predeterminated position of the 3rd charcoal bowl 22, comprehensively compare according to the charcoal bowl design attitude of anode carbon block 27, select one of them center as the 3rd charcoal bowl 22, cutter 4 is moved to this position, and under normal circumstances, cutter 4 does not need to search for again, just can directly enter the 3rd charcoal bowl 26, the program that starts to clear up charcoal bowl 26; If but charcoal piece 27 is when roasting, deformation comparison is large, also need search, but the site error of charcoal bowl 27 has reduced greatly at this moment, started the search utility same with the 4th charcoal bowl and complete the clean-up task of the 3rd charcoal bowl 22, the second charcoal bowl 21 and the first charcoal bowl 20; At this moment, PLC control clamping motor 12 unclamps charcoal piece 26; After having unclamped, signal lamp 10 lights, and prompting pushes next charcoal piece 26, and when the raceway motor was carried next charcoal bowl 26, the charcoal piece 26 that cleaning is completed also was transferred out.
The above; only for the better specific embodiment of the present invention, but protection scope of the present invention is not limited to this, anyly is familiar with those skilled in the art in the technical scope that the present invention discloses; the variation that can expect easily or replacement, within all should being encompassed in protection scope of the present invention.Therefore, protection scope of the present invention should be as the criterion with the protection domain of claims.
Claims (8)
1. power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning, comprise five servomotors that carry absolute encoder, two pressure sensors, torque sensor and visual identity software and hardware system, described five servomotors that carry absolute encoder are respectively spindle servo electric machine, skewed slot servomotor, X-axis servomotor, Y-axis servomotor, Z axis servomotor, it is characterized in that:
Also comprise Programmable Logic Controller, described Programmable Logic Controller is communicated by letter, also by the I/O port, with described pressure sensor, with torque sensor, is connected with five servomotors that carry absolute encoder by fieldbus; X-axis servomotor, Y-axis servomotor, Z axis servomotor in five servomotors that carry absolute encoder form the three degrees of freedom right angle coordinate robot system, be used for carrying the cleaning cutter and realize location, all the other two two kinds of tool motions on the cleaning cutter being controlled respectively;
Also comprise that the original position and the final position that are arranged on the charcoal piece are used for the optoelectronic switch that the charcoal piece is positioned;
Described visual identity software and hardware system comprises the vision system to charcoal piece De Tanwan center and angle of bevel location;
Can control cutter by power Position Hybrid Control method clears up simultaneously to charcoal bowl and skewed slot;
Working angles limits the pressure of vertical direction and the torsion of skewed slot cutter, closed loop PID control by torsion and the motion of skewed slot cutter has been realized the power Position Hybrid Control, make the skewed slot cutter can be in cutting decline process, automatically rotate cleaning when realizing charcoal bowl and skewed slot along the hand of spiral of skewed slot.
2. the power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning according to claim 1 is characterized in that:
The optoelectronic switch that is arranged on charcoal piece final position has two, for detection of the charcoal piece, puts in place and leaves with the charcoal piece, realizes doing coordinating of mode with the original production lineman.
3. the power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning according to claim 1 is characterized in that:
Determine employing vision system and the image recognition software of Tan Wan center and angle of bevel position obtain coordinate, then with the motor of the described three degrees of freedom right angle coordinate of Controlled by Programmable Controller robot, carry out tool setting search realization.
4. according to claim 1 or 3 described power Positioning Servo System that realize anode carbon block for aluminium electrolysis charcoal bowl automation cleaning is characterized in that:
Vision system obtains charcoal bowl coordinate time single charcoal bowl is taken pictures respectively, obtains the relative coordinate of charcoal bowl, then take encoder for servo motor numerical value as reference, calculates absolute coordinate.
5. according to claim 1 or 3 described power Positioning Servo System that realize anode carbon block for aluminium electrolysis charcoal bowl automation cleaning is characterized in that:
Control system adopts the test method under the power restrictive condition to search for the position of charcoal bowl, be that cutter often moves and moves a step in search procedure, cutter test contact charcoal piece, and stop after reaching certain contact force, judge highly by pressing down whether cutter aims at Tan Wan center and skewed slot position.
6. the power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning according to claim 5 is characterized in that:
During the physical location at Controlled by Programmable Controller three degrees of freedom right angle coordinate robot searches Tan Wan center, adopted a kind of grid type traversal search mode, i.e. grid division centered by coordinates computed, carry out tool setting with fixed step size in X and Y-direction and sound out.
7. the power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning according to claim 1 is characterized in that:
The measurement of charcoal tile height is to utilize the method for cutter contact charcoal piece to realize, namely cutter presses down and read force sensor data, and when cutter contacted with charcoal piece upper surface, the encoder numerical value by the Z axis servomotor can access the charcoal tile height.
8. the power Positioning Servo System that realizes anode carbon block for aluminium electrolysis charcoal bowl automation cleaning according to claim 1 is characterized in that:
Have the dual touch screen operation interface, wherein touch industrial computer display screen is used for operation charcoal bowl image recognition software and monitors charcoal bowl situation, and graphic control panel is used for operation, control and the process monitoring of whole system.
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| NO336059B1 (en) * | 2012-12-27 | 2015-05-04 | Sinvent As | Method and apparatus for cleaning carbon anodes |
| CN106802623A (en) * | 2016-12-30 | 2017-06-06 | 天津思博科科技发展有限公司 | Using the production line monitoring system of internet of things sensors |
| CN108563185A (en) * | 2018-03-13 | 2018-09-21 | 深圳市腾浩科技有限公司 | PCB digital control processings control system and its torque knife-breaking detecting method |
| CN112501654B (en) * | 2020-11-19 | 2022-02-22 | 中国铝业股份有限公司 | Automatic carbon anode carbon bowl feeding system and automatic carbon anode carbon bowl feeding method |
| CN112689375A (en) * | 2021-01-12 | 2021-04-20 | 南京工业大学 | Multi-shaft variable-speed adjustment synchronous control method of low-cost titanium liquid refining plasma gun |
| CN112958509A (en) * | 2021-04-09 | 2021-06-15 | 湖南嘉品源智能科技有限公司 | Multifunctional cutter for cleaning carbon electrode |
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| CN102071437A (en) * | 2011-03-01 | 2011-05-25 | 北方工业大学 | Aluminum electrolytic anode carbon block and carbon cup cleaning system |
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| CN101390027A (en) * | 2006-02-23 | 2009-03-18 | Abb公司 | A system for controlling the position and orientation of an object in dependence on received forces and torques from a user |
| CN102071437A (en) * | 2011-03-01 | 2011-05-25 | 北方工业大学 | Aluminum electrolytic anode carbon block and carbon cup cleaning system |
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